5S

How to implement

Objective

The objective of this presentation is to introduce the 5S and what it can contribute to an organization and

how to implement it

Table of contentsPart 1Introduction

Part 2 How to implement

Part 3 How to motivate people to practice 5S

INTRODUCTION

Part 1

What is 5S ? 5S is a visual method of workplace organization

It is a systemized approach to organized areas

Importance of 5S

5S helps to improve

Quality - Prevent errorsProductivity - Eliminates waste Safety - Prevent accidents Equipment reliability - Eliminate maintenance breakdowns

Importance of 5S contd…. Have needed material, tools, supplies, and documentation at

hand, organized and identified

Maintain a clean work area with tools and equipment in top condition

Standardize workplace organization

Why Implement 5S ?

Shortens the span times Reduces the value added work of searching for materials,

tools, equipment and paperwork Reduces floor space requirements Prevents and detects errors and defects Raises team pride and job satisfaction

Why Implement 5S ? Contd…… Makes work easier to accomplish In short, an organized work space Enhances safety Improves quality And reduces cost and cycle time

THE ‘5S’ 1S - Sort

2S – Set in Order

3S - Shine4S - Standardize

5S - Sustain

1S – Sort

Sort is an action to identify and eliminate all unnecessary items from your workplace

“when in doubt, through it out”

Sorting Policies Eliminating obstacles to make work easy Eliminate the need to take care of unnecessary items Provide no chance of being disturbed with unnecessary items Prevent accumulation of unnecessary items

Sorting and evaluation criteria

Sorting criteria

Low use

Things not used in the past year Dispose properly

Things used only once in past 6-12 months Store at a distance

Average use

Things used only in the past 2-6 months Store in a central place

Things used more than once a month Store in a central place

High use

Things used once a week Store near work site or carried by the person

Things used everyday Store near work site or carried by the person

Things used every hour Store near work site or carried by the person

2S Set in Order

Set in Order Is an action to put all the necessary items in good order

“A place for everything and everything in its place”

Set in Order policies Make things easy to locate, easy to put away, readily apparent if

missing No wasted time looking for tools or documents, they are identified

and on hand when needed Nothing that is used daily is stored more than a step away. Improve economy of motion, save valuable seconds, and make the

job less frustrating Arrange the immediate work area layout to minimize twisting,

especially applicable for bench work.

3S Shine

Shine is also an action to clean your workplace thoroughly, clean everything

inside and out

“inspection through cleaning”

Shine policies

• Don’t wait until things get dirty. Clean your workplace including machines and equipment, tools and furniture regularly so that they do not have a chance to get dirty• A clean workplace promotes pride and demonstrates an interest in

quality• Cleaning allows us to find problems with equipment and tools in time

to prevent delays• A bright, clean, organized work area that promotes confidence,

quality and on time delivery

4S Standardize

Standardize is a condition where high standard of good house keeping is maintained, so there is no dust and

rust anywhere

“everything in a state of readiness”

Standardize Policies

• Document the standard method for workplace organization so we always do things in the same way• Standardizing the way we maintain a work area and perform our work

promotes consistency in how work is approached and accomplished, and allows easier cross training and movement of personnel

5S Sustain

Sustain is a systemized approach to maintain discipline through systems and supportive culture

“Launching quality with persistence”

Sustain Policies

• Without sustaining the first 4S will die• It promotes a continuous improvement environment• Ever improving quality, cycle times, on time commitments; high

motivation and recognition for excellence • Visuals help tell at-a-glance the state of the workplace (signs, posters,

arrows, charts, schedules etc.)• Plan for success

IMPLEMENTATION

Part 2

Getting started….

• Set 5S goals• Appoint 5S champion(s)• Post 5S team roaster with leader, champions, and backups for

calibration, shelf life, job supplies• Create a 5S holding area

SORTeliminate nonessential items from the workplace

Target outcomeAn uncluttered workplace

Action steps

1. Identify a 5S project area and take “before” pictures2. Review sorting criteria3. Create a local red tag area4. Tag, record, and remove red tagged items5. Identify items can/cannot be red tagged6. Make team and give 5S responsibilities7. Establish sorting criteria 8. Allocate time for sorting9. Take “after” pictures

Progress check

1. “Before” pictures taken2. Anything from the work area that’s not in use has removed3. “After” pictures taken

Set in Order (planning phase)Evaluate the workplace and add smart workplace features

Target OutcomeA workplace that is visually instructive and is the source of minimal

waste and human errors

Action steps

1. Create a current state workplace diagram2. Evaluate current workplace3. Create a future state workplace diagram4. Get approval for change 5. Target benefits of proposed changes clearly defined

Progress check

1. Improvement opportunities listed, discussed, and prioritized

• waste reduction ideas(e.g., excess motion, material handling etc.)• error reduction ideas (e.g., checklists, visual instructions, or color coding)• Ideas for making the workplace more visually instructive• Ideas to overcome challenges and problems identified

Set in Order (implementation phase)Create a well ordered, visually instructive work place

Target OutcomeA workplace that is visually instructive and is the source of minimal

waste and human errors

Action steps

1. Take “before” pictures2. Implement workplace changes3. Mark locations by creating addresses and applying labeling, marking

and color coding4. Take “after” pictures

Progress check

1. “Before” pictures taken2. Plant marking standards determined3. 5S team clear on plan (e.g., goals/tasks/assignments)4. Reorganization tasks completed (e.g., equipment moved, inventory

relocated)5. Marking and identification tasks completed 6. “After” pictures taken

Shine Define clean

Target OutcomeA clean workplace

Action steps

1. Define clean2. Identify target area for cleaning3. Take “before” pictures4. Clean the work area5. Take “after” pictures6. Record key cleaning points7. Inspection

Progress check

1. Team has established their definition for ‘clean’ in the target workplace

2. Housekeeping staff consulted about cleaning3. Cleaning tasks completed 4. Observation shared among team members about inspection activity

Standardize Establish standards to maintain 5S improvments

Target OutcomeDevelop procedures, checklists, and other mechanisms established to maintain a work environment that is visually instructive, has minimal

waste and human error, and is clean, uncluttered and organized

Action steps

1. Update documentation to update changes2. Make sure all stakeholders are aware of the new standards-inform

and educate

Progress check

1. Documents created or updated, for example • Workplace diagrams• Flow charts• Procedures• Work instructionsJob aids2. Information and/or training provided to stake holders to assure understading

Sustain Monitor, expand and refine 5S results

Target Outcome A workplace that automatically restores orders, regulates activity, and

continuously improves

Action steps

1. Monitor processes established during S4 standardize2. Expand 5S efforts to other work areas3. Evaluate 5S efforts and continuously improve4. Recognize and reward strong efforts

Progress check

1. Sustain methods clearly defined, with responsibilities and target dates identified

2. Sustain actions implemented, for example • 5S teams present projected results• Company leaders conduct 5S audits to see accomplishments and

opportunities

How to motivate people to practice 5S

Part 3